Additive Manufacturing

PYDAH COLLEGE OF ENGINEERING
(Approved by AICTE, New Delhi and Affiliated to JNTUK, Kakinada)

YANAM ROAD, PATAVALA KAKINADA, 533461, E.G.Dist,
Department of Mechanical Engineering
Course File Enclosures
Year /Sem: IV-II Name of the Subject: Additive Manufacturing
S.No Contents
1 Vision & Mission of College
2 Vision & Mission of Department
3 Course Objectives & Outcomes
4 Syllabus
5 Roll List
6 Class Time Tables
7 Subject Time Tables
8 Academic Callender
9 Lesson Plan
10 Lecture Notes
11 Question Bank
12 Assignment Questions
13 Mid Question Papers
14 Previous University Question Papers
15 Previous Question Paper
16 Topics Beyond Syllabus
17 Internal Marks
18 Best and Worst Mid Answer Scripts
19 List of e-resources
20 Result Sheet published by university
21 Pass Percentage
22 Sample Assignment Sheet
23 Attainment Sheet
24 DVD with Video lectures, PPT etc.,
25 Course Completion Certificate
Pydah College of Engineering
Vision
 To equip the students to face both professional and technical competition across the globe with
complete confidence and the necessary skills.
Mission
 To impart value-based education by integrating holistic teaching and learning with innovative
practices.
 To make students compete in the changing global scenario to realize their dreams.
 To create a conducive environment for the students to acquire skills beyond the curriculum in
their interested areas.
Vision
 To provide students with the information, abilities, morals, and empathy they need to overcome
obstacles in their personal and academic lives.
 To be a center of excellence in higher education with creative teaching, learning, and research
activities; to meet students' academic demands by offering high-quality instruction that will
enable them to become self-sufficient in the long run.
 To adopt a comprehensive strategy for the development of interpersonal and intrapersonal
abilities, which are necessary to establish a fruitful, intelligent and innovative civil society.
Mission
 To maximize human potential in order to take advantage of many future prospects.

 To give the students the opportunity to investigate the economic resources that is readily
available in their community for both employment and societal assistance.
 To improve the recently implemented teaching and learning process for staff, faculty, and
students.
 To help students become more autonomous and critical thinkers so they can overcome a variety
of obstacles.
 To produce and distribute knowledge via creative inquiry and multidisciplinary study in order to
build a meaningful society.
Course Objectives & Outcomes
Course Objectives:
1) To understand the principles of prototyping, classification of RP processes and liquid-based RP
systems
2) To understand and apply different types of solid-based RP systems.
3) To understand and apply powder-based RP systems.
4) To understand and apply various rapid tooling techniques.
5) To understand different types of data formats and to explore the applications of AM processes in
various fields
Course Outcomes:
CO1: Understand the principles of prototyping, classification of RP processes and liquid-based RP
systems.
CO2: Understand and apply different types of solid-based RP systems.
CO3: Apply powder-based RP systems.
CO4: Analyze and apply various rapid tooling techniques.
CO5: Understand different types of data formats and explore the applications of AM processes in
various fields.
SYLLABUS
UNIT– I:
INTRODUCTION: Prototyping fundamentals, historical development, fundamentals of rapid

prototyping, advantages and limitations of rapid prototyping, commonly used terms, classification of
RP process.
LIQUID-BASED RAPID PROTOTYPING SYSTEMS: Stereo lithography Apparatus (SLA):

models and specifications, process, working principle, photopolymers, photo polymerization, layering
technology, laser and laser scanning, applications, advantages and disadvantages, case studies. Solid
Ground Curing (SGC): models and specifications, process, working principle, applications, advantages
and disadvantages, case studies.
UNIT– II:
SOLID-BASED RAPID PROTOTYPING SYSTEMS: Laminated object manufacturing (LOM) -

models and specifications, process, working principle, applications, advantages and disadvantages,
case studies. Fused deposition modelling (FDM) - models and specifications, process, working
principle, applications, advantages and disadvantages, case studies.
UNIT– III:
POWDER BASED RAPID PROTOTYPING SYSTEMS: Selective laser sintering (SLS): models
and specifications, process, working principle, applications, advantages and disadvantage studies.
Three-dimensional printing (3DP): models and specifications, process, working principle,
applications, advantages and disadvantages, case studies.
UNIT– IV:
RAPID TOOLING: Introduction to rapid tooling (RT), conventional tooling Vs RT, Need for RT.
rapid tooling classification: indirect rapid tooling methods: spray metal deposition, RTV epoxy tools,
Ceramic tools, investment casting, spin casting, die casting, sand casting process. Direct rapid tooling:
Direct AIM, LOM Tools, and Direct Metal Tooling using 3DP
UNIT– V:
RAPID PROTOTYPING DATA FORMATS: STL Format, STL File Problems, consequence of
building valid and invalid tessellated models, STL file Repairs: Generic Solution, other Translators,
and Newly Proposed Formats.
RP APPLICATIONS: Application in engineering, analysis and planning, aerospace industry,

automotive industry, jewelry industry, coin industry, GIS application, RP medical and bioengineering
applications: customized implants and prosthesis, forensic sciences.
TEXT BOOKS:
1.Rapid prototyping: Principles and Applications /Chua C.K., Leong K.F. and LIM
C.S/World Scientific publications
REFERENCES:
1. Rapid Manufacturing / D.T. Pham and S.S. Dimov/Springer
2. Wohlers Report 2000 /Terry T Wohlers/Wohlers Associates
3. Rapid Prototyping & Manufacturing / Paul F.Jacobs/ASME Press
4. Rapid Prototyping / Chua and Liou

Students Roll List
S.No Regd.no Name Of the Candidate

1 196T1A0303 DEVI CHINTAPALLI
2 196T1A0304 SRI RAMULU KAKARAPALLI
3 196T1A0305 ABHIRAM KATE
4 196T1A0306 PRABHAVATHI MATTAPARTHI
5 196T1A0307 SMITHANJALI NAYAK
6 196T1A0308 JAGADEESH VINAY KRANTHI
7 196T1A0309 MANOHAR SETTIBATTULA
8 196T1A0310 ANVAR SHEIK
9 196T1A0311 DURGA MALLESH
10 196T1A0312 RAVI TEJA YALLA
11 206T5A0301 CHODISETTI SAIRAM
12 206T5A0302 KUNISETTI SURESH GOPI
13 206T5A0303 NEKURI JAGADESH
14 206T5A0304 TAMILSETTI SIVA SANKAR
15 206T5A0305 U.V.V.S. MANIKANTA
16 206T5A0306 VEMAGIRI KUMAR
Signature of the HOD Signature of the principal

CLASS TIME TABLE

6T (Approves by AICTE, Newdelhi & Affiliated to JNT University Kakinada)
KAKINADA, Yanam Road, Patavala – 533461.
IV B.TECH II SEM (R19) A.Y: 2022-23
Class Incharge: Ms.BKSVS MADHURI Room No: 215 w.e.f: 02/12/2022
Hrs 1 2 3 4 5 6 7
Day/Time 09:15 - 10:05 10:05 - 10:55 10:55 - 11:10 11:10 - 12:00 12:00 - 12:50 12:45 - 01:45 01:45 - 02:35 02:35 - 03:25 03:25 - 04:15
NDE AMFG BREAK AM ECM PROJECT
MONDAY
PROJECT AMFG ECM LIBRARY
TUESDAY
PROJECT AM AMFG AM
WEDNESDAY
LUNCH
AM NDE ECM AMFG PROJECT
THURSDAY
BREAK
NDE AMFG NDE ECM PROJECT
FRIDAY
PROJECT NDE ECM AM
SATURDAY
SUBJECT NAME Subject code NAME OF THE FACULTY Sign. Faculty
Additive Manufacturing AMFG KOTIKA SOMARAJU
Non Destructive Evaluation NDE VV RAMA KRISHANA
Energy Consumption and Management ECM N JAYARAM
Advanced Materials AM KSR MURTHY
Project-II PROJECT K SOMARAJU
Signature of Class incharge Signature of HOD PRINCIPAL

SUBJECT TIME TABLE
Hrs 1 2 3 4 5 6 7
Day/Time 09:15 - 10:05 10:05 - 10:55 10:55 - 11:10 11:10 - 12:00 12:00 - 12:50 12:45 - 01:45 01:45 - 02:35 02:35 - 03:25 03:25 - 04:15
MONDAY AMFG
TUESDAY AMFG
WEDNESDAY AMFG
BREAK LUNCH
THURSDAY AMFG
FRIDAY AMFG
SATURDAY
ACADEMIC CALENDER
Lesson Plan
Unit CO Teaching
NO Name of the Topic No. of Classes
No Aid
INTRODUCTION: Prototyping fundamentals,
Black
historical development, fundamentals of rapid
Board & 2
prototyping,
Chalk
Black
Advantages and limitations of rapid prototyping,
Board & 2
commonly used terms, classification of RP process.
Chalk
LIQUID-BASED RAPID PROTOTYPING
SYSTEMS: Stereo lithography Apparatus (SLA): Black
Models and specifications, process, working principle, Board & 2
1 1
photopolymers, photo polymerization, PPT
Layering technology, laser and laser scanning, Black

applications, advantages and disadvantages, case Board & 2
studies. Chalk
Solid Ground Curing (SGC): models and Black
specifications, process, working principle, Board & 2
Chalk
Black
Applications, advantages and disadvantages, case
Board & 2
studies
PPT
SOLID-BASED RAPID PROTOTYPING SYSTEMS: Black
Laminated object manufacturing (LOM) - Board & 2
Chalk
Black
Models and specifications,
Board & 2
Chalk
Black
Process, working principle,
2 2 Board & 2
Chalk
Black
Applications, advantages and disadvantages. Board & 1
Chalk
Black
Case studies.
Board & 1
PPT
Black
Fused deposition modelling (FDM) Board & 1
Chalk
Black
Models and specifications, process Board & 1
Chalk
Black
Working principle, applications, Board & 1
Chalk
Black
Advantages and disadvantages, case studies
Board & 1
Chalk
POWDER BASED RAPID PROTOTYPING Black
SYSTEMS: Selective laser sintering (SLS) Board & 2
Chalk
Models and specifications, process, working principle, Black
Board & 2
Chalk
Black
3 Applications, advantages and disadvantages, case Board & 2
studies. PPT
3
Three-dimensional printing (3DP): models and
Black
specifications, process,
Board & 2
PPT
Black
Board & 2
Working principle, applications, Chalk
Advantages and disadvantages, case studies. Black
Board & 2
Chalk
RAPID TOOLING: Introduction to rapid tooling (RT), Black
conventional tooling Vs RT, Need for RT. Board 3
&PPT
Rapid tooling classification: indirect rapid tooling Black
methods: spray metal deposition Board & 2
Chalk
RTV epoxy tools, Ceramic tools, investment casting, Black
4 spin casting, die casting, sand casting process. Board & 2
4 Chalk
Black
Board & 2
Direct rapid tooling: Direct AIM, LOM Tools, and Chalk
Black
Board & 3
Direct Metal Tooling using 3DP. Chalk
RAPID PROTOTYPING DATA FORMATS: STL
Black
Format, STL File Problems, consequence of
Board & 2
building valid and invalid tessellated models,
Chalk
5
STL file Repairs: Generic Solution, other Translators, Black
and Newly Proposed Formats. Board & 3
Chalk
RP APPLICATIONS: Application in engineering,

analysis and planning, aerospace industry, Black
Automotive industry, jewelry industry, coin industry, Board & 3
GIS application, RP medical and Chalk
Bioengineering applications: customized implants and

prosthesis, forensic sciences
Total Hours 56
Lecture Notes
Question Bank
1. What are the fundamental principles of prototyping, and how has its historical development shaped
modern rapid prototyping techniques?
2. Explain the working principle of Stereo lithography Apparatus (SLA) in detail.
3. What are the specifications and components of an SLA system, and how do they contribute to its
functionality?
4. Describe the process of photopolymerization and its role in SLA technology.
5. How does layering technology function within SLA systems, and what advantages and limitations
does it present?
6. What are the models and specifications of Laminated Object Manufacturing (LOM) systems, and
how do they contribute to the prototyping process?
7. Describe the process and working principle of LOM technology in detail.
8. What are the common applications of LOM, and how does it benefit various industries?
9. Discuss the advantages and disadvantages of LOM compared to other rapid prototyping methods.
10. Provide examples of case studies demonstrating successful applications of LOM technology.
11. What are the models and specifications of Selective Laser Sintering (SLS) systems, and how do
they facilitate rapid prototyping?
12. Explain the process and working principle of Selective Laser Sintering (SLS) technology.
13. How is Selective Laser Sintering (SLS) utilized in various industries, and what are its primary
applications?
14. Discuss the advantages and disadvantages of Selective Laser Sintering (SLS) compared to other
rapid prototyping methods.
15. Provide examples of case studies demonstrating successful applications of Selective Laser
Sintering (SLS) technology.
16. Explain the concept of direct Rapid Tooling and its significance in the manufacturing industry.
17. Describe direct Rapid Tooling methods such as Direct AIM, LOM Tools, and Direct Metal
Tooling using 3DP.
18. Analyze the advantages and limitations of direct Rapid Tooling methods.
19. Compare indirect and direct Rapid Tooling methods in terms of their suitability for different
applications.
20. Provide examples or case studies illustrating the successful implementation of both indirect and
direct Rapid Tooling methods in various manufacturing scenarios.
21. Explain the STL format and its significance in rapid prototyping.
22. Identify common problems associated with STL files and their consequences.
23. Analyze the impact of building both valid and invalid tessellated models on the rapid prototyping
process.
24. Discuss methods for repairing STL files, including generic solutions, alternative translators, and
newly proposed formats.
25. Explore the engineering applications of rapid prototyping, including design validation and product
development.
Assignment Questions
1. Discuss the role of lasers and laser scanning in SLA processes.
2. What are the common applications of SLA technology, and how does it benefit various industries?
3. Compare and contrast the advantages and disadvantages of SLA and Solid Ground Curing (SGC)
rapid prototyping systems.
4. Explain the working principle of Solid Ground Curing (SGC) systems and their applications.
5. Provide examples of case studies showcasing the successful implementation of SLA and SGC
technologies in real-world scenarios.
6. What are the models and specifications of Fused Deposition Modelling (FDM) systems, and how do
they differ from other rapid prototyping technologies?
7. Explain the process and working principle of FDM technology.
8. How are FDM systems utilized in various industries, and what specific applications do they serve?
9. Analyze the advantages and disadvantages of FDM compared to alternative rapid prototyping
methods.
10. Present case studies highlighting the successful implementation of FDM technology in real-world
scenarios.
11. What are the models and specifications of Three-Dimensional Printing (3DP) systems, and how do
they differ from other rapid prototyping technologies?
12. Describe the process and working principle of Three-Dimensional Printing (3DP) technology.
13. How are Three-Dimensional Printing (3DP) systems used in various industries, and what specific
applications do they serve?
14. Analyze the advantages and disadvantages of Three-Dimensional Printing (3DP) compared to
alternative rapid prototyping methods.
15. Present case studies highlighting the successful implementation of Three-Dimensional Printing
(3DP) technology in real-world scenarios.
16. Explain the concept of Rapid Tooling (RT) and compare it to conventional tooling methods.
17. Identify the reasons why Rapid Tooling (RT) is necessary in modern manufacturing.
18. Classify Rapid Tooling methods into indirect and direct approaches.
19. Describe the indirect Rapid Tooling methods, including spray metal deposition, RTV epoxy tools,
ceramic tools, investment casting, spin casting, die casting, and sand casting processes.
20. Discuss the advantages and limitations of indirect Rapid Tooling methods.
21. Describe the applications of rapid prototyping in the automotive industry, such as concept
modeling and functional testing.
22. Discuss the use of rapid prototyping techniques in the jewelry and coin industries for creating
intricate designs.
23. Explore the application of rapid prototyping in Geographic Information Systems (GIS) for creating
physical models.
24. Explain the medical and bioengineering applications of rapid prototyping, including customized
implants and prosthetics.
25. Discuss the role of rapid prototyping in forensic sciences for creating physical replicas of evidence.
Mid Question papers

IV B.Tech I Semester I MID Examinations
ADDITIVE MANUFACTURING
MECHANICAL ENGINEERING
Time : 90 Mins Max. Marks:30 Date:

S.No Note: Answer All Questions Marks BTL CO PO
Discuss the role of lasers and laser scanning in
1. SLA processes. 10 L2 CO1 PO1, PO 2
What are the models and specifications of Fused

PO1 , PO 2,
2. Deposition Modelling (FDM) systems, and how 10 L2 CO 2
PO 3
do they differ from other rapid prototyping
What are the models and specifications of Three-
technologies?
Dimensional Printing (3DP) systems, and how do PO1, PO 2,
3. 10 L2 CO 3
PO 3
they differ from other rapid prototyping
technologies?
IV B.Tech I Semester II MID Examinations
ADDITIVE MANUFACTURING
MECHANICAL ENGINEERING
Time : 90 Mins Max. Marks:30 Date:

S.No Note: Answer All Questions Marks BTL CO PO
Explain the concept of Rapid Tooling (RT) and
1. compare it to conventional tooling methods. 10 L2 CO3 PO1, PO 2
Discuss the advantages and limitations of indirect

PO1 , PO 2,
2. Rapid Tooling methods. 10 L2 CO 4
PO 3
Discuss the role of rapid prototyping in forensic PO1, PO 2,
3. 10 L2 CO 5
sciences for creating physical replicas of PO 3
evidence.
Previous University Question Papers
Topics beyond Syllabus
1. Advanced Materials in Rapid Prototyping
2. Multi-Material and Multi-Functional Prototyping
3. Hybrid Prototyping Systems

4. Generative Design and Optimization for Rapid Prototyping
5. Additive Manufacturing for Electronics
6. In-Situ Monitoring and Quality Control
7. Post-Processing Techniques
8. Sustainability and Environmental Impact
9. Regulatory Considerations and Standards
10. Applications in Emerging Industries

Internal Marks
Best and Worst Mid Answer Scripts
List of e-resources
1. https://home.iitk.ac.in/~nsinha/Additive_Manufacturing%20I.pdf
2. https://application.wiley-vch.de/books/sample/3527347917_c01.pdf
3. https://www.youtube.com/watch?v=EHvO-MlzAIM
4.
https://www.youtube.com/watch?v=9b5Uoejj190&list=PLglMrxSI8n87f0zOOrlOWv9
XYByRi1DlL
Result Sheet published by university

Pass Percentage
S.No No.of Students Attended No.of Pass % Pass

1
Sign of Faculty Sign of HOD

Sample Assignment Sheet
Attainment Sheet
DVD with video lectures, PPT etc.,
Course Completion Certificate
I, , faculty in the department of Mechanical have taught ADDITIVE
MANUFACTURING subject to students of IV B.tech - II sem and Mechanical during academic year
2022-23.I certified that I have completed FIVE units on ________

Signature of Faculty Signature of HOD
Date: Date:

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PYDAH COLLEGE OF ENGINEERING

(Approved by AICTE, New Delhi and Affiliated to JNTUK, Kakinada)

Department of Mechanical Engineering

Course File Enclosures

Year /Sem: IV-II Name of the Subject: Additive Manufacturing

Pydah College of Engineering

Department of Mechanical Engineering

 To maximize human potential in order to take advantage of many future prospects.

Course Objectives & Outcomes

1) To understand the principles of prototyping, classification of RP processes and liquid-based RP

2) To understand and apply different types of solid-based RP systems.

3) To understand and apply powder-based RP systems.

4) To understand and apply various rapid tooling techniques.

CO1: Understand the principles of prototyping, classification of RP processes and liquid-based RP

CO2: Understand and apply different types of solid-based RP systems.

CO3: Apply powder-based RP systems.

CO4: Analyze and apply various rapid tooling techniques.

INTRODUCTION: Prototyping fundamentals, historical development, fundamentals of rapid

LIQUID-BASED RAPID PROTOTYPING SYSTEMS: Stereo lithography Apparatus (SLA):

SOLID-BASED RAPID PROTOTYPING SYSTEMS: Laminated object manufacturing (LOM) -

RP APPLICATIONS: Application in engineering, analysis and planning, aerospace industry,

C.S/World Scientific publications

1. Rapid Manufacturing / D.T. Pham and S.S. Dimov/Springer

2. Wohlers Report 2000 /Terry T Wohlers/Wohlers Associates

3. Rapid Prototyping & Manufacturing / Paul F.Jacobs/ASME Press

4. Rapid Prototyping / Chua and Liou

Students Roll List

S.No Regd.no Name Of the Candidate

Signature of the HOD Signature of the principal

CLASS TIME TABLE

PYDAH COLLEGE OF ENGINEERING

Signature of Class incharge Signature of HOD PRINCIPAL

SUBJECT TIME TABLE

Layering technology, laser and laser scanning, Black

RP APPLICATIONS: Application in engineering,

Bioengineering applications: customized implants and

2. Explain the working principle of Stereo lithography Apparatus (SLA) in detail.

4. Describe the process of photopolymerization and its role in SLA technology.

7. Describe the process and working principle of LOM technology in detail.

1. Discuss the role of lasers and laser scanning in SLA processes.

7. Explain the process and working principle of FDM technology.

Mid Question papers

PYDAH COLLEGE OF ENGINEERING

IV B.Tech I Semester I MID Examinations

Time : 90 Mins Max. Marks:30 Date:

What are the models and specifications of Fused

PYDAH COLLEGE OF ENGINEERING

IV B.Tech I Semester II MID Examinations

Time : 90 Mins Max. Marks:30 Date:

Discuss the advantages and limitations of indirect

Previous University Question Papers

Topics beyond Syllabus

1. Advanced Materials in Rapid Prototyping

2. Multi-Material and Multi-Functional Prototyping

3. Hybrid Prototyping Systems

4. Generative Design and Optimization for Rapid Prototyping

5. Additive Manufacturing for Electronics

6. In-Situ Monitoring and Quality Control

8. Sustainability and Environmental Impact

9. Regulatory Considerations and Standards

10. Applications in Emerging Industries

Best and Worst Mid Answer Scripts

Result Sheet published by university